Contents

General information

• DDECI System
• DDEC II System
• DDEC III / IV Systems
• Basic technical data
• Engine model, serial number and option plate
• Replacement and repair
• Dismantling the engine
• Washing
• Preparing for the first launch
• Launch

Engine maintenance

• Daily maintenance
• Lubrication system
• Fuel tanks
• Fuel lines
• Cooling system
• Turbocharger
• Battery
• Drive belts
• Air compressor
• Air filter
• Cooling system filter and pump
• Intake system
• Release system
• Engine (steam wash)
• Radiator
• Oil pressure
• Battery charging system generator
• Powertrain mounts
• Blow-by gas pressure
• Fan clutch
• Insulation and seals
• Oil separator for crankcase ventilation
• Engine adjustments
• Compressed air intercooler / auxiliary pump
• Heat exchanger
• Fuel heat exchanger (fuel cooler)
• Fuel injectors
• Vibration damper (damper)
• Generator and its mounts
• Air conditioner compressor and mounting
• Air compressor and its mounting
• Periodic maintenance of car engines

DDEC Electronic control system

• System description
• System functions
• System components
• Location of system components
• System diagnostics
• General information
• Reading codes using control lamps
• Reading codes using the diagnostic panel
• Fault code table
• Preparing for troubleshooting
• Troubleshooting by codes
• Electrical connectors and diagrams
• Electronic module
• Engine wire harness connector
• Engine wire harness diagram
• Vehicle interface wiring harness connector
• Car interface wiring diagram
• ECM power connector and wiring diagram with one fuse
• ECM power connector and wiring harness diagram with two fuses
• Communication harness connector
• Injector connector and wiring diagram
• Connector and circuit for engine brake with ECM
• Diagnostic panel
• Functions of the electronic module
• Function blocking
• Function blocking scopes
• Function lock password
• Working with the diagnostic panel
• Diagnostic codes
• Cylinder shutdown sequence
• Injector calibration update
• Reprogram calibration
• Snap function
• Print
• Control lamps
• Yellow control lamp does not work
• The yellow indicator lamp remains on
• The yellow control lamp flashes irregularly and intermittently
• The yellow control lamp lights up for up to seconds
• The yellow control lamp does not light up
• Troubleshooting by symptoms
• Diagnostic hardware for DDEC IV and DDEC V
• Description
• DDEC IV Trouble codes
• DDEC V Trouble codes
• Abbreviations and terms

Repair manual

Removing the engine

• Valve cover
• Removing a conventional valve cover
• Removing the valve cover with base
• Removing the valve cover with base and spacer
• Valve cover installation
• Installing a valve cover with base and spacer
• Cylinder head
• Removing the cylinder head
• Turbocharger oil lines
• Leak test
• Check for flatness of the block head
• Installing the cylinder head

Cylinder block

• Connecting rod-piston group
• Removing pistons and connecting rods
• Disassembly
• Cast iron pistons
• Steel pistons
• Build
• Cast iron pistons
• Steel pistons
• Installing a connecting rod with a piston in the engine
• Installation of pistons in l engine
• Pistons and piston rings
• Disassembling the piston
• Piston assembly
• Installing piston rings
• Rods
• Closed head connecting rod
• Checking the connecting rod
• Checking bearings
• Cylinder liners
• Removing the sleeve
• Cleaning and checking cylinder liners
• Installation
• Crankshaft main bearings
• Withdrawal
• Main bearing check
• Installation
• Crankshaft
• Removing the crankshaft
• Checking
• Runout measurement
• Neck diameter measurement
• Method using magnetic particles
• The method using fluorescent magnetic particles
• Liquid method with phosphor
• Bending fatigue
• Torsion fatigue
• Cracked crankshaft
• Installation
• Crankshaft oil seals
• Removing the front oil seal
• Removing the rear oil seal (with the flywheel housing installed)
• Federal mogul seal
• CR seal
• Installing the front and rear crankshaft oil seal
• Flywheel housing
• Withdrawal
• Installation
• Flywheel
• Withdrawal
• Checking
• Installation
• Replacing the ring gear
• Withdrawal
• Installation
• Crankshaft pulley
• Removing the crankshaft pulley
• Checking
• Installation
• Damper
• Checking the vibration damper
• Damper installation
• Valve and injector drive mechanism
• Removing the rocker arms
• Inspection
• Installation
• Adjusting valve clearances, engine brake and injector heights
• Valve adjustment procedure and nozzle height setting
• Control parameters
• Valves, springs, guides, valve seats, caps and valve rotators
• Removing valves
• Removing the guides
• Removing the intake and exhaust valve seat
• Valve check
• Checking the springs
• Checking rails and seats
• Installing intake and exhaust valve seats
• Installing valve guides
• Installing the valve, spring, cap and valve turning mechanism
• Timing case cover
• Removing the timing case
• Checking
• Installing the timing case cover
• Installation of noise insulation
• Timing gear case
• Removing the gear housing
• Installing the gear housing
• Timing gears and engine timing
• Gear Synchronization
• Check engine timing
• Auxiliary drive gear and main gear meshing clearance
• Main gear and water pump gear meshing clearance
• Air compressor main gear meshing clearance
• Build
• Camshaft thrust plate seal
• Withdrawal
• Installation
• Camshaft and camshaft bearings
• Removing the camshaft and bearings
• Installing the camshaft
• Checking the camshaft end play
• Installation
• Valve timing control
• Camshaft gear
• Removing the camshaft gear
• Checking
• Installation
• Main gear and idler camshaft gears
• Removing the main and intermediate gears
• Checking
• Installation
• Adjustable idler gear
• Withdrawal
• Checking
• Installation
• Crankshaft gear and cogwheel
• Withdrawal
• Checking
• Installing the crankshaft gear
• Auxiliary drive
• Withdrawal
• Disassembly
• Checking
• Build
• Engine brake
• Removing the engine brake (model)
• Installing the engine brake
• Setting auxiliary piston clearance
• Engine brake

Injectors

• Removing the nozzle
• Disassembly
• Checking
• Repair
• Installing a nozzle
• Fuel injector bowl & o-ring
• Installing an additional seal
• Bowl and o-ring installation
• Checking
• Fuel pump
• Withdrawal
• Disassembly
• Checking
• Build
• Installing the fuel pump
• Installing an air compressor driven fuel pump
• Fuel pump drive
• Removing the drive
• Installing the drive
• Fuel filters
• Replacing the fuel filter
• Removal / installation
• Water separator replacement
• Fuel filter FUEL PRO / E
• Fuel filter and water separator
• Fuel return control valve
• DDEC III / IV Engine electronic control unit (ECM)
• Replacing the DDEC III / IV electronic control unit
• Removing the control unit
• Installation
• Turbocharger pressure sensor
• Oil pressure sensor
• Oil temperature sensor
• Air temperature sensor
• Removing the air temperature sensor
• Coolant temperature sensor
• Speed ??sensor
• Crankshaft position sensor
• Coolant level sensor
• Fuel temperature sensor
• Tightening torques

Lubrication system

• Oil pump
• Removing the oil pump
• Disassembly
• Build
• Installation
• Oil pressure regulating valve
• Withdrawal
• Disassembly
• Build
• Installation
• Oil pressure reducing valve
• Oil filter
• Oil filter support
• Thermostatic valve
• Oil cooler
• Oil dipstick
• Oil pan
• Removing the oil pan
• Installation
• Crankcase ventilation system
• Withdrawal
• Installation

Cooling system

• Water pump
• Removing and disassembling the water pump
• Installation
• Thermostat
• Removing thermostats
• Opening and full opening temperatures
• Fan
• Removing the fan hub
• Installation
• Radiator

Air system

• Air filter
• Air separator
• Intake manifold
• Removing the intake manifold
• Intake manifold installation
• Turbocharger
• Withdrawal
• Disassembly
• Checking
• Removing the bypass valve actuator
• Installing the drive
• Bypass valve installation
• Assembling the turbocharger
• Installation
• Intermediate air cooler
• Exhaust manifold
• Removing the exhaust manifold
• Installing the exhaust manifold

Electrical equipment

• Generator
• Removing the generator
• Installing the generator
• Battery
• Withdrawal
• Installation
• Starter
• Removing the starter
• Installation
• Tachometer drive
• Power take-off shaft
• Air compressor
• Removing the compressor
• Installation
• Specifications
• Cylinder block (dimensions in mm)
• Sleeve
• Piston and Rings
• Piston and rings (l engine)
• Crankshaft
• Connecting rod bearings
• Main bearings
• Camshaft
• Camshaft bearings
• Camshaft gear
• Crankshaft gear
• Main gear
• Exhaust Valve Seats
• Inlet valves
• Exhaust valves
• Valve Guides
• Rocker arms and axles
• Rocker rollers
• Tightening torques

Engine parts catalog detoit diesel 60 series

• Engine models and serial numbers
• Table of correspondence of model and serial numbers of engines to numbers of groups and types of parts used in them
• Parts catalog